Automotive vehicle seat insert

• US 20060152044A1
• Filed: 02/17/2006
• Published: 07/13/2006
• Est. Priority Date: 07/03/2002
• Status: Active Grant

• Current Assignee: Gentherm GmbH (Gentherm Incorporated)
• Original Assignee: WET Automotive Systems Limited (Gentherm Incorporated)
• Inventors: Drobnjakovic, Valerija, Bajic, Goran, Lazanja, Marinko, Fernandez, Lucas, Liss, Anne Patrice, White, Brennon Lewis, Brennan, Lindy
• Granted Patent: US 7,197,801 B2
• Time in Patent Office: Days
• US Class Current: 297/180.140
• CPC Class Codes: B60N 2/56 Heating or ventilating devices
• CPC Class Codes: B60N 2/5635 coming from the passenger compartment
• CPC Class Codes: B60N 2/5642 with circulation of air through a layer inside the seat
• CPC Class Codes: B60N 2/5657 blown towards the seat surface
• CPC Class Codes: B60N 2/5685 Resistance
• CPC Class Codes: Y10T 29/48 Upholstered article making
• CPC Class Codes: Y10T 29/481 Method

Abstract

There is disclosed an insert suitable for placement within a seat of an automotive vehicle. The insert preferably includes multiple layers, one of which includes a heater for providing an occupant of the seat with warmth. The insert also preferably includes a blower or air pump for providing ventilation and/or cooling to the seat occupant.

Claims

1-40. -40. (canceled)

41. A method for manufacturing an insert for providing ventilation of a seat, comprising the steps of:

providing a first polymeric gas barrier layer having a plurality of openings for fluidly communicating with an air permeable seat cover, an intermediate layer including a spacer material, and a second polymeric gas barrier layer wherein either the first barrier layer or the second barrier layer includes at least one opening for fluidly communicating with an air mover; and

laminating the first and second barrier layers about a peripheral edge of the insert for defining a peripheral strip extending about the insert and for confining the spacer material within the first and third layer so that the spacer material forms an open space within the insert wherein the spacer material remains at least partially pliable or flexible between the first and the second layers.

42. The method of claim 41 wherein the strip has a width between about 0.2 cm and about 3 cm.

43. The method of claim 41 wherein the strip has a width between about 1.0 cm and 2.0 cm

44. The method of claim 41 wherein the laminating step includes adhering the first and second layers together by an adhesive including a material selected from polyamides, polyesters, elastomers, urethanes, olefin polymers or a combination thereof.

45. The method of claim 41, further comprising a step of attaching a heater to insert.

46. The method of claim 45 wherein the attaching step includes laminating a heater layer to the first layer.

47. The method of claim 46 wherein the heater layer includes a lay wire heater, a carbon fiber heater, a positive thermal coefficient (PTC) heater, or a thermoelectric heater.

48. The method of claim 46 wherein the heater layer includes thin and flat heater elements.

49. The method of claim 48 wherein the heater layer includes a positive thermal coefficient (PTC) heater.

50. The method of claim 41 further comprising a step of forming an air permeable layer over the first barrier layer.

51. The method of claim 41, further comprising a step of attaching the insert to the air mover with an attachment component including a frame member defining an opening or through hole.

52. A method for manufacturing an insert and providing ventilation of a seat of an automotive vehicle, comprising the steps of

providing a first polymeric gas barrier layer having a plurality of openings, an intermediate layer including a spacer material and a second polymeric gas barrier layer wherein either the first barrier layer or the second barrier layer includes at least one opening;

laminating, by adhesion or melt seal, the first and second barrier layers about a peripheral edge of the insert for defining a peripheral strip extending about the insert and for confining the spacer material within the first and third layer so that the spacer material forms an open space within the insert wherein the spacer material remains at least partially pliable or flexible between the first and the second layers;

providing an air mover in fluid communication with the at least one opening; and

placing the plurality of openings in fluid communication with an air permeable seat cover of a seat of an automotive vehicle.

53. The method of claim 52 further comprising a step of attaching a wire harness to the insert.

54. The method of claim 52 wherein the resulting area of the plurality of openings in the first layer are within 20 cm² of the resulting area of the at least one opening.

55. The method of claim 52 wherein the resulting area of any cross section of air space defined by the spacer substantially perpendicular to air flow through the spacer is within 30 cm² of the resulting area of the at least one opening in the third layer.

56. The method of claim 52 wherein the air mover is attached to an extension of the insert and the insert is free of any heater.

57. The method claim 52 wherein the first and second layers are adhesively bonded together with a hot melt adhesive.

58. The method of claim 52 wherein the air mover is adapted to pull air through the openings in the first layer and the open space.

59. The method of claim 52, further comprising a heater layer wherein the spacer material is formed with rubber, foam, plastic or fibers and the heater layer includes a positive thermal coefficient (PTC) heater.

60. A method for manufacturing an insert and providing ventilation of a seat of an automotive vehicle, comprising the steps of

providing a first polymeric gas barrier layer having a plurality of openings, an intermediate layer including a spacer material, and a second polymeric gas barrier layer wherein either the first barrier layer or the second barrier layer includes at least one opening;

adhering the intermediate layer to the first barrier layer, the second barrier layer or both;

laminating a heater layer to the first barrier layer;

laminating, by adhesion or melt seal, the first and second barrier layers about a peripheral edge of the insert for defining a peripheral strip extending about the insert and for confining the spacer material within the first and third layer so that the spacer material forms an open space within the insert wherein the spacer material remains at least partially pliable or flexible between the first and the second layers;

providing an air mover in fluid communication with the at least one opening; and

placing the plurality of opening in fluid communication with an air permeable seat cover of a seat of an automotive vehicle.

61. The method of claim 60, wherein:

i. the spacer is formed of a polymeric strand material confined between opposing fabric panels;

ii. providing the air mover in fluid communication includes attaching the air mover to the insert with a snap fit; and

iii. wherein the strip is between about 1.0 cm and 2.0 cm.

62. The method of claim 61 further comprising:

i. providing a control unit programmed with instructions for commanding the air mover, means for seat heating or both to change output levels if a temperature sensor senses a temperature above or below one or more threshold levels; and

ii. forming a tape pocket and securing a wire harness to the insert within the tape pocket;

wherein;

i. the gas barrier layer is formed of closed pore foam;

ii. the insert is formed with a gauze, a cloth or fleece outer layer;

iii. the air mover is adapted to blow air through the openings in the first layer and the open space;

iv. the first layer and the second layer are formed of a film having a thickness of 0.1 mm to 2.0 mm; and

v. the first and second layers are formed with through holes that are sealed.